IK1201243 ­ MaxxForce 7 Internal Coolant Leak Diagnostics and Repair

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Countries:

CANADA, UNITED STATES, MEXICO Document ID: IK1201243

Availability:

ISIS, Bus ISIS, FleetISIS

Revision:

1

Major System:

ENGINES

Created:

11/20/2014

Current Language: English

Last Modified: 3/25/2015

Other Languages: NONE

Author:

Viewed:

Aaron Mimbs

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Title : MaxxForce 7 Internal Coolant Leak Diagnostics and Repair
Applies To : ALL MaxxForce 7

CHANGE LOG
03/20/2015 - ADDITIONAL CLEANING STEPS TO HELP ADDRESS FAILURES DUE TO BLOCK CLEANLINESS
02/16/2015 - Initial Article Release

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DESCRIPTION
This document will guide the user through internal coolant loss diagnostics and block repair steps for the MaxxForce 7.
This document replaces/retires: IK1201218 - 2010 V-8 Internal Coolant Leak Diagnostics
Belzona Reforming and Protective Materials for Engines and Castings (Testimonials)

SYMPTOMS
Diagnostic Trouble Code(s) & Dashboard Indicator Light(s):
2007­2009 MaxxForce 7
DTC/Light

SPN/Light

Description

SPN 2323 FMI 1 SPN 111 FMI 1 ECL below Warning / Critical Level
SPN 2321 FMI 0 SPN 110 FMI 0 Engine Coolant System above Critical Temperature
SPN 2322 FMI 7 SPN 110 FMI 7 Engine Coolant System above Warning Temperature

2010­2013 MaxxForce 7
SPN/Light

Description

SPN 111 FMI 1

ECL below Warning / Critical Level

SPN 110 FMI 0

Engine Coolant System above Critical Temperature

SPN 110 FMI 15 Engine Coolant System above Warning Temperature
SPN 110 FMI 16 Engine Coolant System Above OBD Maximum Temperature

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IK1201243 ­ MaxxForce 7 Internal Coolant Leak Diagnostics and Repair

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SPN 110 FMI 17 Engine Coolant System below OBD monitoring temperature

SPN 110 FMI 18

Engine Coolant System below closed loop minimum
temperature

Customer Observations or Concerns:
- Coolant loss
- Coolant consumption
­ Coolant in the oil
- Engine over-heat

SPECIAL TOOLS / SOFTWARE
Tool
Number

Tool Description

Comments Instructions

EZ-TECH OR POCKETMAXX
BORESCOPE

LOCALLY

COOLANT MANAGEMENT SYSTEM (CMT)
SMALL ABRASIVE FLAP DISC
NOZZEL SLEEVE SEATING BRUSH
PRESSURE TESTER
10MM SOCKET
13MM SOCKET
8MM HEX BIT SOCKET

REQUIRED.
RECOMMEND: SNAP-ON
BORESCOPE BK6500

KL5007NAV
LOCALLY
ZTSE4391
ZTSE2384

No larger than 20mm in diameter
For scrubbing coolant cavity

LOCALLY
LOCALLY
LOCALLY

PUNCH

LOCALLY

HAMMER
PRY BAR
PLYERS
HEAT GUN
ABRASIVE DISC (SCOTCH-BRITE)
FREEZE PLUG INSTALLER
STANDARD PLUG

LOCALLY
LOCALLY
LOCALLY
LOCALLY
LOCALLY

REQUIRED
Removing paint from block (External)

ZTSE4509
LOCALLY

DISPOSABLE MEASURING SPOON

MUST BE 1 TABLESPOON
LOCALLY

(1 TABLESPOON - 15 mL)

(FUTURE KITS MAY CONTAIN)

SERVICE PARTS INFORMATION
Kit Description
1KG BELZONA 1391 HT
CERAMIC EPOXY
KIT, MXF7 BLOCK REPAIR
(MECHANICALS)
BREATHER, ASSY IMPACTOR
INTERNATIONAL T-442 RTV
SILICONE RUBBER

Part Number

Quantity
Required

Notes

2514564C1

150 grams

Kit comes in 1kg quantities, dealer must divide epoxy
appropriately for each repair (5-6 repairs per container)

2514509C91

1 Per Repair

Kit Contents (Click Here)

7085773C92

As Needed

Follow article diagnostics (2010-2013 MF7)

1830858C1

As Needed

DIAGNOSTIC STEPS
Step Action

Decision

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IK1201243 ­ MaxxForce 7 Internal Coolant Leak Diagnostics and Repair

1

Initial checks

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Yes. Proceed to Step 2

Obtain vehicle health report using EZ Tech or Pocketmaxx
Has vehicle health report been obtained and uploaded?

Step Action
Contamination verification
Drain the oil into a clean pan.
2
Is coolant visually present in the engine oil?

Step Action
Leak Inspection
Remove the engine oil pan per instruction is the Engine Service Manual
3

Using tool ZTSE2384 - Radiator Pressure Test Kit, pressurize the cooling system
per procedure listed in the Engine Diagnostic Manual and inspect for leaks near
cylinder 7.
Is there a coolant leak present near cylinder 7?

Step Action
Post Repair Diagnostics - Crankcase Pressure

Decision
Yes. Proceed to Step 3
No. Follow Coolant System symptom
section of the Engine Diagnostic Manual.

Decision
Yes. Proceed to the Repair Steps section
of this document
Leaks but Not Near Cylinder 7. Step 6 ­
NOTE: Repairing the engine may still be
directed but in a different location.
No Leaks. Follow Coolant System
symptom section of the Engine Diagnostic
Manual

Decision
Document Result - Step 5

Perform the following: Crankcase Pressure Test at engine operating
temperature of 158°F (70°C) or higher.

4

1. Ensure the oil level is not above the full mark.
2. Remove the oil level gauge from the dipstick tube. Attach 11/16" hose with
clamps and 1/4" pipe adapter to magnahelic gauge on gauge kit ZTSE4409.
3. Start engine and run at high idle (no load) RPM. Allow reading to stabilize, before
recording reading.
Refer to the Diagnostic Manual.
Specification: at High Idle, Below 24" of H2O

Step Action
5

Post Repair Diagnostics ­ Blow­By

Decision
Crankcase Pressure: In Spec
Blow-By: In Spec

Perform the following: Blow-By Test at engine operating temperature of 158°F No action necessary, complete any other
(70°C) or higher.
required work and release unit to the
customer.
1. Ensure the engine oil level is not above the full mark and the oil level gauge is
Crankcase Pressure: Out of Spec
secured.
Blow-By: In Spec
2. With engine OFF, remove oil fill cap.
3. Install crankcase pressure test adapter ZTS4284 to oil fill tube.
Remove Crankcase Breather:
4. Connect orifice ZTSE4146A to crankcase pressure test adapter ZTSE4284.
5. Connect a line from the orifice ZTSE4146A to the magnahelic gauge on the
Part Number 7085773C92: Clean
gauge kit ZTSE4409.
breather of sludge or debris. If
6. Using a standard plug, block off the road draft tube, located on the bottom right uncleanable or no sludge resent replace
side of the engine.
the breather.

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IK1201243 ­ MaxxForce 7 Internal Coolant Leak Diagnostics and Repair

7. Run engine at high idle (no load) RPM. Monitor magnahelic gauge and record
high idle blow-by pressure.

Part Number 7085773C91: Replace
Breather with 7085773C92

Refer to the Diagnostic Manual.

Blow-By: Out of Spec

Specification: at High Idle, Below 9" of H20

Step 6

Step Action
Engine iApproval Process
Open an engine replacement iApproval using the Service Portal be sure to include
the following information
6

Page 4 of 23

Decision
Follow Navistar's Technical Support
Teams directions. This may include
following through with the remainder
of this article.

1. Fill out a detail description of the issue.
2. List any active & Inactive DTCs
3. Attach images of the leak and if the repair was attempted pictures of the cleaned
galley and epoxy in the galley
4. Obtain and attach the engine parameter file
5. Note any other details observed (over-heat, over-speed, etc.)

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IK1201243 ­ MaxxForce 7 Internal Coolant Leak Diagnostics and Repair

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REPAIR STEPS
WARNING
To prevent personal injury or death, read all safety instructions in the "Safety Information" section of the diagnostic manual.
WARNING
Park vehicle on hard flat surface, turn the engine off, set the parking brake, and block the wheels to prevent the vehicle from
moving in either direction. Failure to do so may result in property damage, personal injury, and / or death.
WARNING
To prevent personal injury or death, make sure the engine has cooled before removing components.
WARNING
To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand cleaner and
wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids.
WARNING
This procedure may require the usage of an open flame and flammable materials. Please use extreme caution and ensure full
dissipation of flammable substances before using an open flame.
WARNING
Always wear safe eye protection when performing vehicle maintenance. Failure to do so may result in personal injury and / or
death.

FAILURE CONCLUSIONS:
Coolant leaks were a result of perforation due to corrosive attack.
TEST/ANALYSIS RESULTS:
All of the failures occur only in a low spot of the water jacket of Cylinder #7 near the coolant plug shown in Figure 1. Notable amounts of
debris can also be found in the coolant passage.
The failures were cavities of varying size as shown in Figure 1. When a failure occurs, a cavity would grow large enough to perforate the
wall separating the coolant and oil, allowing coolant from the water jacket to enter the oil passage.
SUMMARY
The failures were consistently in the area of the coolant plug only near cylinder #7. Small cavities and large cavities had similar graphite
morphology and had corroded surfaces. The non­failed parts had an as­cast surface in the typical failure areas and no failure inducing
defects were found. Filling the effected area with Belzona 1391 HT Ceramic Based Epoxy prevents coolant leakage and further corrosion
of the block.

Figure 1: Coolant Jacket Comparison Cylinders #7 and Cylinder #8

Before You Begin
The coolant cavity has to be clean and dry for the epoxy to adhere to the surface. Please do not guess or assume the cavity is
clean, be diligent with the prep work. This repair works; failures occur by not following the cleaning and inspecting steps and

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the customer's truck will be down again for a short block engine replacement with even more time lost. All repair failures will
be looked at by Navistar to determine the root cause of the repair failure.

Repair Failure Examples

Figure 2: Failure due to improper corrosion removal

Figure 3: Failure due to oil contamination

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